Coated microwave heating sheet

ABSTRACT

A coated sheet material is provided for wrapping, packaging or shipping food articles that are to be heated in a microwave oven. The sheet is formed from a paper or paperboard backing which is thermally and dimensionally stable when exposed to microwave energy. On at least one side is provided a smooth calendered surface or the sheet material is treated by processing as with a filler coating to fill the voids between the paper fibers and to thereby present a smooth surface. A microwave interactive layer is applied to the smoothed surface from a fluid or vapor state. The interactive coating can comprise carbon, a semiconductive metal coating or other microwave interactive material.

This is a continuation of application Ser. No. 07/212,235, now U.S. Pat.No. 5,006,405 filed 6-27-88.

FIELD OF THE INVENTION

The present invention relates to sheet material and more particularly tocoated sheets that are useful in packaging and shipping products.

BACKGROUND OF THE INVENTION

The present invention is concerned with the problem of providing coatedpaper which can be used in sheet form or in the form of a bag or othercontainer for heating articles in a microwave oven. Many products havebeen proposed for browning, searing or otherwise heating the surface ofan article within a microwave oven. These prior products can be dividedinto three groups: rigid; semi-flexible or having limited flexibility;and flexible. Rigid heating containers are exemplified by the followingU.S. Pat. Nos. 4,266,108; 4,184,061; 4,450,334; 4,398,077; 4,166,208;4,158,760; and 4,320,274. Among these, U.S. Pat. No. 4,266,108 describesa reflective metal plate such as an aluminum plate to which a layer oflossy materials, e.g. magnetic oxides known as ferrites, have beenapplied. These materials are bonded to the reflective metal plate whichcan be aluminum by means of an intermediate layer containing a binder onan air gap. U.S. Pat. No. 4,184,061 describes a glass ceramic browningvessel with a metallic oxide coating on its lower surface. U.S. Pat. No.4,450,334 is similar, except that in this case a plastic layercontaining a ferrite is applied to the bottom surface of an aluminumdish. In U.S. Pat. No. 4,398,077 a ceramic or glass dish is describedhaving a resistive film 14 of tin oxide applied to its lower surface.Both of U.S. Pat. Nos. 4,166,208 and 4,158,760 describe rigid conicalcontainers formed from plastic. The lower end of each cone is in contactwith the support member such as a block of plastic which is made lossyby the inclusion of metal or carbon particles. U.S. Pat. No. 4,320,270describes a cooking utensil in the form of a dielectric dish, e.g.,glass or plastic, having a metal layer extending through it.

Among references describing flexible packaging materials is U.S. Pat.No. 4,190,757 which describes a supporting substance in the form ofaluminum foil which may be as little as one mil in thickness to which apaint-like layer of a ferrite or other lossy material is applied as acoating. For example, a wet mixture of taconite, sand and sodiumsilicate are blended and applied by brushing and rolling the compositiononto a sheet of three mil aluminum to a thickness of 0.03 inches. Theresulting laminate is fairly thick (over 30 mils in thickness) and isdifficult to handle with automated roll stands and other equipment usedfor winding, rolling, cutting, transferring and forming sheet materialinto packages. Moreover, the laminate is heavy and the ferrite coatingsometimes tends to flake off when the underlying aluminum sheet is bentor flexed.

U.S. Pat. Nos. 4,267,420 and 4,230,924 describe the use of thin carriersheets comprising flexible polyester plastic films or laminates ofpolyester and polyethylene to which a thin semiconductive metal coatingis applied. The carrier sheet can, if desired, be bonded to paperboard.U.S. Pat. Nos. 4,553,010, 4,555,605, 4,641,005, 4,678,882 and 4,735,513show other coated sheets and laminates in which a microwave interactivematerial is supported upon or dispersed within a carrier sheet formedfrom plastic.

By contrast with the prior art, a major objective of this invention isto find an effective means for applying microwave interactive coatingsto a paper or paperboard backing, for convenience referred to hereinsimply as "paper", without the use of a separate sheet of metal foil orplastic film as a support or carrier for the interactive layer. Thus, inaccordance with the prior art, an interactive substance such as metal,metal oxide, carbon, etc., is either deposited upon a separate plasticcarrier sheet, e.g. polyester, or distributed within a film of plastic,e.g. polyethylene or polyethylene tetrathalate, which is in turn bondedto a paper backing sheet. In the work leading to the development of thepresent invention it was found that when a microwave interactivematerial, such as an electrodeposited metal layer or carbon, is appliedto paper directly there is a tendancy for sparking, popping, arcing andburning to occur when the sheet is exposed to microwave energy. This isof course unacceptable.

One major objective of the invention is to find a way to eliminate theseparate plastic sheet used previously as a carrier for the microwaveinteractive material. Another object is to provide a novel coated sheetmaterial having a cellulose backing coated with a microwave interactivematerial in such a way that the interactive material will uniformly heata product, e.g. a food packaged in the sheet material without causingexcessive arcing, sparking, popping, scorching or burning of thecellulose sheet material when exposed to microwave energy in a microwaveoven.

It is a more specific objective of the present invention to provide animproved cellulose sheet suited for packaging purposes and for producingheat in a microwave oven that does not require a separate plastic sheetfunctioning as a carrier for microwave interactive material that has tobe laminated to the cellulose sheet but which has the followingcharacteristics and advantages:

(a) the ability to absorb microwave energy and transfer the absorbedenergy to products in a microwave oven during a heating process withoutsparking, shrinking, burning, shriveling or disintegrating;

(b) the ability to perform satisfactorily although portions of the sheetextend away from and out of heat transfer relationship with the productbeing heated;

(c) the ability to carry out heating in certain selected areas and notin others;

(d) the provision of areas of any selected shape such as rectangular,triangular, hexagonal, circular areas, etc., that are capable of heatingwhile other surrounding areas of a flexible sheet have no heatingfunction.

(e) provisions which make possible printing all coating layers,including microwave interactive material, onto a paper backing using acommercially available printing press.

These and other more detailed and specific objects and advantages of theinvention will become apparent in view of the following detaileddescription and accompanying drawings which set forth by way of examplecertain illustrative embodiments of the invention.

THE FIGURES

FIG. 1 is a semidiagrammatic cross-sectional view of a typical containerutilizing sheet material in accordance with the invention.

FIG. 2 is a highly magnified or microscopic view of coated sheetmaterial in accordance with another form of the invention.

SUMMARY OF THE INVENTION

Briefly, the invention provides a flexible sheet structure formed from abacking sheet composed of a microwave transparent cellulosic sheet ofpaper or paperboard upon which is provided one or more areas coated witha microwave coupling material that absorbs microwave energy and becomeshot when exposed to microwave energy. When applied to the surface of anarticle, e.g. food, to be heated, the article will absorb heat byconduction from the sheet in selected areas where the layer of microwavecoupling material is provided but the sheet will allow the product toheat by direct microwave exposure through the flexible sheet material inuncoated areas. The coupling layer can comprise a coating applied from afluid, e.g. liquid, state such as an ink or if desired a layer depositedby vacuum electrodeposition or electroplating.

More specifically, in one preferred embodiment of the invention thesheet structure comprises a backing sheet of paper or paperboardmaterial transparent to microwaves rendered sufficiently free ofdiscontinuities to be coated with a heating layer that will not arc, popor burn under normal microwave heating of food. This can be accomplishedin several ways, e.g. by supercalendaring the paper until glossy or bythe application of a filler coating to fill the voids between the fibersin the paper. After harmful discontinuities are removed, a coating ofmicrowaveabsorbing coupling, i.e. heating, material is applied to theexposed surface of the sheet. In one form of the invention a cellulosicbacking sheet such as paper, cardboard or paperboard is coated with aclay filler coating and then with a pore-sealing coating which is inturn coated with a microwave interactive heating layer. In another form,paper is coated with the interactive layer directly and then coated witha heat insulating layer.

In one form of the invention the area of the interactive layer is thesame size and shape as the paper while in another form of the inventionthe coated area of the sheet is smaller than the sheet of paper orpaperboard and its size and shape are carefully selected to producespecial benefits.

The coated area may be of any selected shape, such as rectangular,triangular, circular, etc., but is usually the shape of the food productor other product to be heated. For example, if the product being heatedis a hamburger patty, a coated patch or island of microwave couplingmaterial will have the shape and size of the hamburger patty and can beplaced directly beneath it. The uncoated portions of the sheetsurrounding the coated patch can be folded up around the sides of thefood or sealed to a similar sheet which lies in contact with the topsurface of the food product.

By contrast with the prior art, the sheet material of the presentinvention requires no separate plastic carrier and laminating operationwherein a layer of plastic sheet material is pressed or bonded onto thepaper backing. In a typical situation the sheet material of the presentinvention is placed around a food product such as a hamburger patty,french fries, etc., and is heated in a microwave oven for 4 to 6minutes. After heating, the sheet material remains intact and is notdamaged or discolored as a result of sparking or burning. Moreover, heatis transferred very effectively to the food or other product and inspite of the high temperature reached, the paper is not usuallydiscolored, charred or otherwise damaged during the heating process.This effectiveness is primarily due to the smooth surface substantiallyfree of pores or other discontinuities provided for the interactiveheating coat.

Islands or patches of various shapes can be printed onto the paperbacking using commercially available printing presses. The islands orpatches of microwave coupling material should have the same size andshape as the food or other product being heated and be in contact withthe food more or less uniformly in order to prevent damage to the sheetdue to overheating in localized areas.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Refer now to the Figures which illustrate one embodiment of theinvention and the method used for forming it.

Islands or patches of microwave coupling material which become hot whenexposed to microwave energy comprise a coating applied from a fluidstate such as an ink or by electrodeposition as a metallic film. FIG. 1illustrates one preferred form of the invention. In FIG. 1 is shown asheet of paper 10, e.g. 50-lb/ream kraft paper which is preferablysupercalendared. When it is employed, the optional supercalendaringoperation renders the sheet smooth and substantially free of surfacediscontinuities at least on its outside (lower) surface. The sheet 10 isfolded and suitably sealed to itself by means of an adhesively bondedlap joint 11 to form a container, in this case a paper bag having afront panel 12 and a rear panel 14 joined together by centrallydeflected gussets 16 and 18. The paper 10 is heat stable within thetemperature range of operation.

Applied to the outside surface of the bottom wall or bottom panel 14 isa coating that may consist of one or more layers. In any event there isat least one coating 20 of a microwave interactive heating substance ofthe type which will become hot in a microwave oven and will transmitheat by conduction through the paper panel 14 to a food product (notshown) within the container. The coating 20 is applied while in a fluidor vapor state to the outside surface of the panel 14 and is thenallowed to cure or set. Coating 20 can be applied in any suitablemanner, as by means of spraying, brushing, roll coating or printing, andprior to application will have the fluid or semi-fluid consistency of aprinting ink and after it is applied will cure in situ. It can be seenthat the coating 20 extends into proximity with the side edges of thepanel 14 but need only be large enough to coincide approximately withthe edges of the food product contained in the package. As seen from theoutside of the package, the coating 20 is a patch which can have anysuitable outline. For example, it can be circular, rectangular, squareor have a special shape, i.e. a predetermined perimeter shapespecifically determined to correspond with the shape of the food productin the package.

The coating 20 can comprise any known coating material adapted tointeract with microwave energy and to become heated through theinteraction. For example, the coating 20 can comprise a matrix orcoating base containing carbon particles or carbon fibers or, ifdesired, metal particles such as aluminum, copper, zinc, nickel, iron,chromium or a metal oxide such as iron oxide, aluminum oxide or tinoxide, or it can comprise any one of a number of ferromagneticsubstances known to produce heating when exposed to microwaves. Thecoating 20 is flexible, non-flaking and is bonded to the surface of thepanel 14. It also conforms to the surface contours of panel 14 and, ifdesired, can be made sufficiently flexible to conform to the contours ofthe food product (not shown) within the package by bending somewhat tofollow its surface irregularities.

In accordance with a preferred optional form of the invention, a secondnon-heating exterior coating layer 21 is applied by spraying, dipping,roll coating or printing to the outside surface of the coating 20.Coating 21 is a protective coating preferably formed from any suitablesubstance having heat insulating properties. It is also preferablyporous to allow gases, vapors or fumes to pass through it. Two generaltypes of coatings are preferred. First, a mineral based coating such asa clay coating. To achieve porosity, it can contain a foaming agent,e.g. a minor amount of a gas-producing substance such as an acid and abase adapted to react during the coating process to generate carbondioxide or other gas for producing voids in the coating. A variety offoaming agents will be apparent to those skilled in the art. Onesuitable foaming agent is a mixture of acetic acid and sodiumbicarbonate introduced just prior to the coating operation. A secondgeneral type of coating is a porous plastic resinous coating such as afoamed polyurethane, polyester, epoxy or other plastic resin. Thus, ingeneral, the coating 21 can comprise any of a variety of flexiblecoatings preferably having heat insulating and/or infrared reflectingproperties. The coating layer 21 can contain other insulating componentssuch as cellulose particles or other bulking agents, e.g. expandedvermiculite and the like.

During manufacture, the first microwave interactive coating 20 isapplied to the sheet 10 by spraying, printing, roll-coating, etc. asdescribed above and is then allowed to cure. Next, the protective heatinsulating overcoating 21 is applied by any of the same methods, e.g.printing, roll coating and the like, to form a heat insulating barrierover the coating 20. It is then allowed to cure, i.e. to form a stablefilm as by means of solvent evaporation, oxidation, the inter-reactionof a two-component system, or polymerization. The layer 20 thus servesas a functional layer for picking up energy while the coating 21 isnon-interactive with the microwave energy except indirectly as aninsulating layer for reducing heat loss.

When the package formed from sheet 10 is placed in a microwave oven andexposed to microwave energy, the coating layer 20 will become intenselyhot and the heat will be carried by conduction through sheet 14 to thefood product to enhance cooking. As this happens, the flexibleovercoating layer 21 can be effective in reducing the loss of heat intwo ways; by reducing conduction of heat downwardly and by thereflection of thermal heat back into the package. Layer 21 in this casecomprises a flexible coating having pores that extend through it toallow any fumes generated in the coating 20 to be exhausted into theatmosphere. To accomplish this, the sheet 10 is made relatively gas andvapor impervious compared with the coating 21. In this way, it ispossible to apply by printing or rollcoating a vapor and gas ventinginsulating layer 21. If desired, the layer 21 can in the alternativecomprise a layer of self-supporting sheet material such as paper,paper-board or synthetic plastic film (50 lb. Kraft paper is typical)bonded, e.g. glued onto the coating 20 to form a three layer sandwichstructure or laminate composed of sheet 14, coating 20 and sheet 21thereby encapsulating the heat producing coating 20 between twoself-supporting sheets. When the overcoating layer 21 is porous it willalso promote the escape of any fumes, gas or vapors from the intenselyhot layer 20 while it is performing the heat insulating function therebyreducing the loss of heat from the package and thus intensify theheating effect achieved by the coating 20. This improves the heating offood within the package by heating the contents more quickly and to ahigher temperature.

Refer now to FIG. 2 which illustrates a highly magnified or microscopiccross-sectional view of another panel 14 in accordance with theinvention. The panel 14 includes a suitable microwave transparent,thermally and dielectrically stable sheet, i.e. dimensionally stablewhen heated in a microwave oven, e.g. paper, to which is applied asurface filler coating 22 that fills in the irregularities andinterstices between the fibers 14a of the panel 14. The support sheet orpanel 14 is typically a sheet of 10 to 80-pound per ream kraft paperoptionally provided with a grease-proofing agent. The surface fillercoating 22 can be a clay coating preferably applied as a fluid orsemi-fluid state, typically an aqueous dispersion, by roll coating,knife coating, spraying, flexographic coating or by other known coatingprocesses to provide a relatively flat exterior surface as shown and tofill in the spaces between the fibers 14a. This gives the coating 22 anirregular thickness. The important characteristics of coating 22 areflexibility, the ability to fill in voids between the fibers 14a and theprovision of a smooth exterior surface. Clay coating compositions per seare well known in the art of paper coating. The filler coating 22,whether of clay or other materials, can if desired be made to haveheating characteristics in a microwave oven.

Applied to the exterior surface of coating 22, either directly or overan intermediate layer 24, is a microwave interactive heat producingcoating 26. While the interactive coating 26 can be applied directly tothe relatively flat exposed surface of the coating 22, it is preferablyapplied to the exposed surface of a second coating 24. The secondcoating 24 is composed of an initially relatively much more fluidcoating material with good leveling properties to produce a smooth andusually glossy, more impervious surface which makes the relativelypermeable clay coating 22 more impermeable. The second coating 24 can bethought of as a pore-sealing coating for producing a continuous,uninterrupted exposed surface. It is to the exposed surface of thepore-sealing coat 24 that the microwave interactive heating layer 26 ispreferably applied. Since the layer 24 is continuous, uninterrupted andhas a smooth glossy surface, the coating 26 can be applied veryuniformly and without breaks, fissures or discontinuities, e.g. pinholesand cracks therein. It appears that the presence of such cracks andpinholes was responsible in the past for unacceptable heatingproperties. However, by using an undercoating 22 or 24 with a smoothexterior surface, the microwave interactive coating, e.g. an interactiveink or lacquer type coating applied from a fluid state or avapor-deposited oxide or metal, the finished coating will be continuous,uniform and uninterrupted. As a result, heating can be accomplishedwithout unacceptable arcing, popping or burning. In this way, thesurface of the microwave transparent base sheet 14 is prepared so thatthe microwave interactive layer 26 can be applied so as to havestructural characteristics that make it stable and non-arcing during theheating process in the microwave oven. The improvement in performance isbelieved to be primarily due to the smooth, glossy and pinhole- orpore-free surface presented for the application of the microwaveinteractive coating 26. This allows a much more uniform coating 26 to beapplied to the surface by the methods mentioned above.

The filler coating 22 can comprise any suitable known clay coating suchas one comprising an adqueous dispersion of clay and starch or a claycoating having a resin content such as an emulsion modifier of acrylicor styrene butadiene or polyvinyl acetate type or of polyvinyl alcoholor it can be composed entirely of a plastic resinous material. Thepore-sealing coat 24 can comprise any relatively fluid plastic resinouscoating having good leveling properties and presenting a relativelyimpervious and usually glossy exposed surface when cured.

The coatings 22 and 24 can contain any of a variety of resins butthermosetting resins are preferred to thermoplastic resins because oftheir heat resistance. By thermoplastic is meant a substance that willdeform enough to lose its useful properties during use. The termthermosetting is meant a product that will undergo a chemical reactionleading to a state that is relatively infusable during use orsufficiently infusable to retain useful properties when heated duringuse. For example, coating 24 can be an alkyd-oil base coating. Thesecoatings use a binder of synthetic resin obtained by reacting an alcoholsuch as glycerine or pentaerytritol with a polybasic acid such asphthalic acid in the presence of a reflux solvent such as xylol toremove the water formed during the reaction. The product can beoil-modified to provide oxidation properties. If desired this syntheticresin can be copolymerized with styrene, vinyl-toluene, acrylic monomersor silicone. Toluene diisocyante may also be reacted with any hydroxylfunctionality to form a product known as urethane-alkyd. Physicalmodification with phenolics or rosin esters is also possible to achieveadvantageous properties. An alkyd-vinyl-toluene copolymer solution intoluene is advantageous in coating 24 because such products become dryenough to handle by solvent evaporation. They display excellent holdouton porous substrates and will further oxidize to become somewhatthermosetting. The alkyd coating, e.g. coating 24, is applied byflexography or by roll coating. Curing is then allowed to occur byoxidation and polymerization. It is desirable to reduce or eliminate theuse of solvents because they tend to promote greater porosity in thesurface of coating 24. If desired, the alkyd coating can be mixed as isknown in the coating art with other polymerizing (reactive) resins, e.g.heat reactive urea, melamine resins, for changing the characteristics ofthe coating layer 24 as required.

Another type of base for coatings 22 and 24 is a phenolic alkyd, i.e. analkyd resin modified with phenols and aldehydes for the purpose ofhardening the alkyd coating. Curing can be accomplished by heating thesheet.

Yet another example is a phenolic resin or phenolic modified resin, i.e.phenol reacted with formaldehyde. This will only cure under heat butcertain reacted phenolics are oil soluble and can be used to modifyalkyds and other coatings.

Another example is a silicone alkyd. In this case an alkyd resin isreacted with silicone to form a silicone copolymer to give the coating24 added heat resistance and gloss. The coating is dried by oxidationand polymerization.

Of the above examples the alkyd-melamine and urea formaldehyde modifiedpolymers must be baked, e.g. 200° F. Other examples are oxidizable oilsor alkyds reacted with toluene diisocyanate. Other polymers aretwo-component or moisture cure systems based upon aromatic or aliphaticdiisocyanate monomers reacted with hydroxyl functional polymers or oils(two-component systems) or with moisture in the air.

Another example of a suitable base for coatings 22 and 24 is apolyurethane resin formed from the reaction of aromatic or aliphaticdiisocyanates with hydroxyl functional polymers applied in a low solventor solvent-free system from two components which are mixed together justprior to application. The coating 24 is cured by reactive cross-linkingand by reaction with moisture in the pre-polymer component of the resin.It is preferred that the use of volatile solvents be minimized becauseof their tendency to produce minute pores produced in the coating duringevaporation.

Still another example of a composition useful in the coating 22 andespecially the coating 24 is an epoxy resin formed by the reaction of anepoxide and an amine or polyamide. A 100% solids resin composition ispreferred to one containing a solvent. This will assure a glossy,pore-free surface. In one coating, biphenol A-epichlorohydrin polymer inwhich a terminal epoxy group is catalyzed by an amine or a polyamide.

Another coating is an epoxy-polyester coating in which the internalepoxy functionality is reacted with highly acidic polymers based onchlorendic anhydride.

Other compositions that can be used are silicone resins, preferablythose that are solvent-free or low in solvents, again to reduce thepresence of pores in the exposed surface.

Still other thermosetting coating resins that will form a thin,relatively non-porous coating will be apparent to those skilled in theart.

The resin can be of a type that is cured rapidly by radiation, such asU.V. radiation, electron beam radiation or by vapor permeation. Anexample of the former is an acrylic monomer-oligomer mixture containingphotoinitiators and sensitizers. For radiation cure, maleicanhydride-styrene polyester is an example. For a vapor permeation cure,high solids urethanes that are catalyzed will cure when exposed totri-ethyl amine vapors.

Following the application of the pore sealing coat 24 the microwaveinteractive layer 26 is applied to the exposed surface of the sheet. Ifthe coating 26 is in a fluid state it is applied by spray coating, rollcoating or printing or the like. If desired, the coating 26 can be ametallic coating applied by sputtering in a vacuum chamber, that is tosay by vacuum electrodeposition to form a thin, uniform, semiconductivemetallic layer.

The invention will be better understood by reference to the followingexamples.

EXAMPLE 1

A sheet 14 comprising 50-pound per ream greaseproof kraft paper iscoated with a commercially available clay coating layer 22 used forcoating paper to fill in the voids between the paper fibers 14a. Theclay coating has the following compositions by weight:

    ______________________________________                                                                  % by                                                                          weight                                              ______________________________________                                         Starch - 17 parts by weight                                                                        Solids         55                                       Clay - 100 parts by weight                                                                          Polyvinyl alcohol                                                                            1                                                              Water          44                                                                           100%                                      ______________________________________                                    

The clay coating 22 provides a substantially smooth exposed surface.After the clay coating is dried, a layer 24 comprising a 0.5 mil thickpore-sealing coating of 100% solids epoxy resin is applied. The resincoating 24 forms a smooth, glossy, nonporous surface which is then curedby heating to 250° F.

The resulting sheet can then be coated with a suitable known microwaveinteractive coating. When heated in a microwave oven it will generate asubstantial amount of heat with little arcing.

EXAMPLE 2

A laminate is prepared similar to Example 1 except that the clay coating22 is a commercially available clay coating used for coating paper towhich is added 10% of a compatible film-forming acrylic resin emulsion.Next is applied a resin coating 24. The resin coating 24 is a phenolicmodified alkyd resin. When heated in a microwave oven, heat is generatedin the sheet with minimal arcing. In another sample, an acrylic latex isused in place of the alkyd resin. In a third sample, an alkyd emulsionresin is used in place of the acrylic emulsion to provide anemulsifiable resin binder for the clay coating.

EXAMPLE 3

The sheet 14 comprises a 30-pound per ream greaseproof kraft paper towhich is applied a commercially available clay filler coating 22 topresent a relatively smooth exposed lower surface. To the filler coating22 is applied a microwave interactive layer 26 comprising a printing inkvehicle having a 20% content of any of the following microwaveinteractive particulate (pigment) materials: carbon black, ironparticles, aluminum particles, iron oxide particles, stainless steelparticles or particles of tin oxide. Resin and pigments are combined tothe extent that the critical pigment volume is slightly exceeded, i.e.the pigment volume is great enough so that there is not enough resin tocoat every pigment particle. The porosity of the coating increasesgreatly at this point, sufficiently to enable vapor, gas and fumesproduced during heating to escape to the outside rather than penetratingthe package and possibly contacting a food product. During use, heat isgenerated without unacceptable arcing.

EXAMPLE 4

A microwave interactive laminate is prepared as in Example 3 except thatan alkyd pore-sealing coat 24 is interposed between the clay coating 22and the coating 26. The pore-sealing coat 24 comprises an alkyd known asa baking alkyd composed of melamine formaldehyde and/or ureaformaldehyde resin. In another sample an epoxy-polyester baking acrylicof the type described above is used. Curing is accomplished by heatingto 350° F. In a third sample, a catalyzed urethane resin is used. Inthis sample, curing is accomplished with tri-ethyl amine vaporpermeation. In a fourth sample, maleic anhydride is reacted with styreneto form a polyester resin. The reaction is promoted by radiationcomprising infrared radiation, ultraviolet radiation or electron beamradiation. The coating 24 is about 0.5 mils in thickness. It presents aglossy surface and is substantially pinhole-free. The interactive layer26 generally as described in Example 3 but without the pigment exceedingthe critical pigment volume is then applied onto this coating. Resultsare as in Examples 1-3.

EXAMPLE 5

A laminate is prepared as in Example 4 except that the microwaveinteractive coating 26 is a coating of a vapor-deposited semiconductivemetal layer applied in a vacuum chamber. In separate samples thefollowing semiconductive metal coatings are applied: aluminum, copper,tin, tin oxide, nickel, iron, zinc, chromium and stainless steel. Theresults are as with previous examples.

EXAMPLE 6

A laminate is prepared as in Example 5 except that a liquid insulationcoating 21 comprising a porous clay coating of 2 mils thickness isapplied by roll coating over the interactive metal layer 26 and is thendried to provide heat insulation and to reflect infrared radiationinwardly. This laminate retains heat better than Example 5 and the foodwill reach a higher temperature when heated in a microwave oven.

EXAMPLE 7

A 60-pound per ream supercalandered kraft paper is coated directly witha vacuum electro-deposited semiconductive layer of aluminum. When heatedin a microwave oven with food adjacent to the coated sheet, arcing isminimal. In a second sample, a coating of a silicone resin is appliedbefore vacuum coating. In a third sample a baking alkyd as described inExample 4 is substituted for the silicone resin coating.

Many variations of the invention within the scope of the appended claimswill be apparent to those skilled in the art once the principlesdescribed herein are understood.

What is claimed is:
 1. A coated microwave heating sheet for wrapping,packaging or shipping food products that are to be heated thereby in amicrowave oven, comprising,a base sheet formed from a microwavetransparent fibrous cellulosic sheet comprising paper or paperboard; atleast one surface of the base sheet being calendered so as to besufficiently smooth and free of surface discontinuities to allowmicrowave heating of the coated sheet material without substantialarcing or sparking; a microwave interactive heating layer composed of amicrowave coupling material applied from a fluid or vapor state as acoating upon the calendered surface of the base sheet; said microwaveinteractive heating layer comprising a microwave interactive compositionthat becomes hot when exposed to microwave energy for transmitting theheat by conduction from the interactive layer to the food product. 2.The coated sheet of claim 1 wherein the calendered sheet is asupercalendered sheet.
 3. The coated sheet of claim 1 wherein theinteractive layer is applied to the surface thereof as a fluid coatingand cured upon the surface of the sheet.
 4. The coated sheet of claim 1wherein the interactive layer is a member selected from (a) a thinmetallic coating applied by vacuum electrodeposition and (b) acarbon-containing layer.
 5. A coated sheet material for wrapping,packaging or shipping food products that are to be heated in a microwaveoven, comprising:a base sheet formed from a microwave transparentfibrous cellulosic sheet of paper or paperboard to be exposed tomicrowave energy in a microwave oven, a coating thereon comprising afiller coating applied to at least one surface of said sheet to fill atleast some voids between the fibers thereof for enhancing the smoothnessof the surface thereof; a microwave interactive heating layer comprisinga microwave coupling material applied form a fluid or vapor state as acoating upon said one side of the sheet material over the filler coatingand forming a layer thereon, said microwave interactive heating layercomprising a microwave interactive composition that becomes hot whenexposed to microwave energy for transmitting the heat by conduction fromthe interactive layer to the food product.
 6. The coated sheet of claim5 wherein the fibrous cellulosic layer comprises paper or paperboard andthe surface filler coating comprising a member selected from a claycoating and a plastic resinous coating applied as a fluid and curedthereon.
 7. The coated sheet of claim 6 wherein the clay coating has aresin content composed of a plastic resinous substance distributedtherein.
 8. The coated sheet of claim 5 wherein interposed between themicrowave interactive layer and the filler coating is an additionalcoating for sealing pores in the filer coating, said second coatingcomprising a plastic resinous layer.
 9. The coated sheet of claim 8wherein the additional pore-sealing coat comprises a plastic resinouscomposition cured in situ and selected from the group consisting ofepoxy resin, epoxy-polyester resin, polyurethane resin, polyester resin,phenolic resin, alkyd resin, alkyd copolymer resin, baking systemscomposed of an alkyd and urea formaldehyde or melamine formaldehyderesin, silicone resin and acrylic resin.
 10. The coated sheet of claim 5wherein the interactive layer contains carbon particles or fibers. 11.The coated sheet of claim 5 wherein the interactive coating is asemiconductive metallic coating.
 12. The coated sheet of claim 11 formedinto a package containing said food product.
 13. A coated sheet forwrapping, packaging or shipping food articles that are to be heated in amicrowave oven comprising, a base sheet composed of paper or paperboard,at least one layer of a filler coating material applied from a fluidstate and cured thereon so as to present a surface that is smoother thanthe original base sheet and being sufficiently free of surfacediscontinuities so that said coated sheet when finished will allowheating in a microwave oven without objectionable arcing or sparking anda microwave interactive coupling layer applied from a vapor state byvacuum deposition onto an exposed surface of the filler coating toprovide a semiconductive coating that becomes hot when exposed tomicrowave energy in a microwave oven whereby the resulting heat iscarried by conduction into the food in contact with or proximate to thecoated sheet.
 14. The coated sheet of claim 13 wherein thesemiconductive layer comprises a member selected from the groupconsisting of vapor deposited aluminum, vapor deposited zinc, vapordeposited tin, vapor deposited copper, vapor deposited nickel, vapordeposited tin oxide, vapor deposited stainless steel and vapor depositedchromium.
 15. The coated sheet of claim 13 wherein the filler coatingcomprises a first coating layer for filling pores and voids between thefibers of the base sheet and a second coating layer is applied to anexposed surface of the first coating layer, said second coatingcomprising a coating of a resinous plastic composition cured in situ toprovide a surface that is smoother than the original surface of the basesheet.
 16. The coated sheet of claim 8 wherein the additional coatingcomprises an initially fluid, substantially solvent-free resin coatingto produce a cured resin matrix.
 17. The coated sheet of claim 6 whereinthe coating applied to the base sheet comprises an initially fluidthermosetting plastic resin.
 18. The coated sheet of claim 5 whereinanother coating layer is applied over the microwave interactive layerform a fluid state and is cured to define an outer protective layercovering the microwave interactive layer.
 19. The coated sheet of claim18 wherein the outer protective layer has heat insulating properties.20. A coated sheet material for wrapping, packaging or shipping a foodproduct that is to be heated in a microwave oven by being placedadjacent to a first surface of said coated sheet material, comprising:abase sheet formed from a microwave transparent fibrous cellulosic sheetthat is thermally, dielectrically and dimensionally stable when exposedto microwave energy in a microwave oven; a microwave interactive heatinglayer comprising a microwave interactive composition that becomes hotwhen exposed to microwave energy to thereby transmit the heat byconduction from the interactive layer to the food product; and a heatinsulating means as a part of the sheet material on the opposite side ofthe sheet from said first surface for reducing the loss of heat from theinteractive layer during heating in said microwave oven.
 21. The coatedsheet of claim 2 wherein the sheet is coated with a coating composed ofa cured fluid having heating properties when exposed to microwave energyin a microwave oven.
 22. The coated sheet material of claim 2 whereinthe sheet material is a laminate having a selfsupporting sheet bondedonto said microwave interactive layer to form a three-layer sandwichstructure thereby encapsulating said microwave interactive coatingbetween the base sheet and the self-supporting sheet.
 23. The coatedsheet material of claim 22 wherein said self-supporting sheet is acellulosic sheet of paper or paperboard.
 24. A coated microwave heatingsheet for wrapping, packaging or shipping food products that are to beheated thereby in a microwave oven, comprising:a base sheet formed froma microwave transparent fibrous cellulosic sheet comprising paper orpaperboard; a microwave interactive heating layer composed of asemiconductive metallic coating applied to a surface of said sheet as apatch upon a portion of the base sheet that is smaller than said sheetand the base sheet having uncoated portions at least partiallysurrounding the coated patch.
 25. The coated sheet of claim 24 whereinthe coated patch has generally the same size and shape of the foodproduct, said uncoated portions of the sheet surrounding the coatedpatch thereby extending away from the coated patch portion of the sheetto be placed adjacent the food product.
 26. The coated sheet of claim 25wherein the metal coating is a semiconductive metallic coating vapordeposited under vacuum onto said backing.
 27. The coated sheet of claim24 wherein preconditioning mans for the base sheet is selected from:(a)a calendered surface to enhance smoothness of the base sheet and (b) afiller coating to fill voids between the fibers in the cellulosic basesheet for enhancing the smoothness of the base sheet to allow microwaveheating of the coated sheet with reduced arcing or sparking thereof.